Wheel FAQs

Response: ECG wheels are classified as either conventional or super abrasive. A conventional ECG wheel is an abrasive (Aluminum Oxide, Silicon Carbide or combination) copper and resin bond. Super abrasive ECG wheels are cermet, diamond or CBN in a metal bond or conductive resin bond form.

2. How long do wheels last?

Response: The ECG process causes much less wheel wear than conventional abrasive grinding. The actual amount of wheel wear will vary depending on the material being cut and the ECG parameters. Wheel wear is expressed as a ‘G’ ration. This is the ration of material removed divided by the amount of wheel consumed. For example, if 10 cubic inches of material are removed and 2 cubic inches of wheel was consumed then the ‘G’ ration is 5. Using a standard aluminum oxide electrolytic wheel cutting stainless steel tubing, a ‘G’ ratio of 10 to 15 would be typical. A diamond or super-abrasive wheel may give a ‘G’ ratio as high as 100.

3. Do you recommend different wheels based on the different types of materials being cut?

Response: Everite has a number of different wheel specs and sizes available. There are also different thicknesses. The standard general purpose wheel is the 10 x .060 A100RBC. This is an aluminum oxide (AlOx) used widely for cutoff of stainless steel tubing. We also make plain silicon carbide (SiC) wheels, combination grit and diamond/CBN. The 10 x .040 thick wheels are also popular for cutoff. These are helpful on cutoff of very small diameter materials or very flexible tubing such as Nitinol. The thinner wheel will put less pressure on the part during the cut and save kerf loss.

4. How does the squareness of the wheel (dress) contribute to non-square ends?

Response: The wheel should always have a good square edge. An angle on the wheel will tend to force it to walk to one side during the cut. Also warped or cupped wheels can cause out of square or uneven cuts.

5. My parts are out of square on one end only. What can cause this?

Response: this condition is usually from a warped or cupped wheel. Note which side of the wheel is producing the non-square cut. Remove the wheel and mount it the opposite way. If the problem follows the wheel then replace the wheel. If the non-square end remains on the same side then there could be a fixture or clamping problem. Uneven electrolyte flow can cause this. Be sure that both sides of the wheel receive even amounts of flow. Also check that the cutoff wheel is centered in the fixture slot too. It is important to make the cutting conditions equal on both sides of the wheel. Possibly the spindle head and/or the spindle motion is not square to the fixture. If this is the case, realignment of the work head may be required.